Cone air filter

ABSTRACT

An apparatus and method are provided for a cone air filter for a closed intake system of an internal combustion engine. The cone air filter includes a cone-shaped filter medium, retained between a base and a cap, that is fabricated to remove contaminants and particulate matter from an intake airstream. The base includes a flange that couples with an air intake duct of the internal combustion engine. A shell receiver is incorporated into the base and receives a rigid exterior shell, such that the exterior shell surrounds the cone air filter and directs the intake airstream therein. A cap is disposed on an apex portion of the cone air filter and is configured to direct the intake airstream around the apex portion and into the cone-shaped filter medium.

PRIORITY

This application claims the benefit of and priority to U.S. ProvisionalApplication, entitled “Cone Air Filter,” filed on Aug. 3, 2016 andhaving application Ser. No. 62/370,525.

FIELD

The field of the present disclosure generally relates to filtrationdevices. More particularly, the field of the present disclosure relatesto an apparatus and a method for a cone air filter for a closed intakesystem of an internal combustion engine.

BACKGROUND

An air filter designed to remove particulate matter from an airstreamgenerally is a device comprising fibrous materials. These fibrousmaterials may remove solid particulates such as dust, pollen, mold, andbacteria from the airstream. Air filters are used in applications whereair quality is important, notably in building ventilation systems andwith engines.

Air filters may be used in automobiles, trucks, tractors, locomotivesand other vehicles that use internal combustion engines. Air filters maybe used with gasoline engines, diesel engines, or other engines thatutilize fossil fuels or other combustible substances. Air filters may beused with engines in which combustion is intermittent, such asfour-stroke and two-stroke piston engines, as well as other types ofengines that take in air continuously so that a combustible substancemay be burned. For example, air filters may be used with some gasturbines. Filters may also be used with air compressors or in otherdevices that take in air.

Filters may be made from pleated paper, foam, cotton, spun fiberglass,or other known filter materials. Generally, the air filters used withinternal combustion engines and compressors tend to be comprised ofeither: paper, foam, or cotton filters. Some filters use an oil bath.Air filters for internal combustion engines prevent abrasive particulatematter from entering the engine's cylinders, where it would causemechanical wear and oil contamination. In many fuel injected engines, aflat panel pleated paper filter element may be used. This filter isusually placed inside a plastic box connected to the throttle body withductwork. Vehicles that use carburetors or throttle body fuel injectiontypically use a cylindrical air filter positioned above the carburetoror throttle body.

SUMMARY

An apparatus and method are provided for a cone air filter for a closedintake system of an internal combustion engine. The cone air filter iscomprised of a cone-shaped filter medium that is retained between a baseand a cap. The cone-shaped filter medium is fabricated to removecontaminants and particulate matter from an intake airstream. The filtermedium may be comprised of paper, foam, cotton, spun fiberglass, orother known filter materials, woven or non-woven materials, synthetic ornatural, or any combination thereof. A filter oil composition may beapplied to the filter medium so as to enhance air cleaning properties ofthe cone air filter. The base is comprised of a flange that isconfigured to couple with an air intake duct of the internal combustionengine. A shell receiver is incorporated into the base and configured toreceive a rigid exterior shell, such that the exterior shell surroundsthe cone air filter and directs the intake airstream therein. A cap isdisposed on an apex portion of the cone air filter and is configured todirect the intake airstream around the apex portion and into thecone-shaped filter medium.

In an exemplary embodiment, a cone air filter for a closed intake systemof an internal combustion engine comprises a base comprised of a flangethat is configured to couple with an air intake duct of the internalcombustion engine; a cap comprising an apex portion of the cone airfilter and configured to direct an intake airstream into the cone airfilter; and a filter medium disposed between the base and the cap, thefilter medium being configured to remove contaminants and particulatematter from the intake airstream entering the air intake duct.

In another exemplary embodiment, a the cone air filter is configured tobe retained within a rigid exterior shell comprising the closed intakesystem, such that the intake airstream is directed between the cap andan interior of the exterior shell, drawn through the filter medium intoan interior of the cone air filter, the contaminants and particulatematter being removed from the intake airstream by the filter medium, anddrawn into the air intake duct to the internal combustion engine. Inanother exemplary embodiment, the cap is comprised of a rounded,cone-shaped member fixedly coupled to an apex portion of the filtermedium that is opposite of the base. In another exemplary embodiment,the cap is comprised of a rigid material suitable for withstanding thetemperature and pressure within the closed intake system, the cap beingconfigured to direct the intake airstream around the apex portion andinto the side of the filter medium.

In another exemplary embodiment, the base includes a shell receiver thatis configured to receive a rigid exterior shell that directs the intakeairstream into the filter medium, the shell receiver being comprised ofa smooth circumferential surface disposed at an extreme diameter of thebase. In another exemplary embodiment, the shell receiver is comprisedof one or more holes that are configured to receive fasteners suitablefor fixedly coupling the exterior shell with the smooth circumferentialsurface. In another exemplary embodiment, the one or more holes arecomprised of four holes that are disposed uniformly around the perimeterof the smooth circumferential surface. In another exemplary embodiment,the base includes a vent inlet receiver configured to receive a ventinlet, such that the vent inlet is placed into fluid communication withan interior of the cone filter. In another exemplary embodiment, thevent inlet is comprised of a flange adapter configured to couple theinterior of the cone filter with any of a PCV valve, a crankcasebreather, and various sensors that are electrically connected with theinternal combustion engine.

In another exemplary embodiment, the flange is comprised of a pliablematerial amendable to being stretched and compressed so as to be coupledwith sizes of the air intake duct that are, respectively, slightlygreater than or lessor than a relaxed interior diameter of the flange.In another exemplary embodiment, the flange is configured to slide ontoan exterior of the air intake duct and be retained thereon by way of asuitable clamp or any other similar fastener. In another exemplaryembodiment, the flange is configured to receive an adaptor into aninterior of the flange, the adaptor being configured to be coupled withthe air intake duct so as to communicate the intake airstream from theinterior of the cone air filter to the air intake duct.

In another exemplary embodiment, the filter medium is comprised ofpaper, foam, cotton, spun fiberglass, or other known filter materials,woven or non-woven materials, synthetic or natural, or any combinationthereof. In another exemplary embodiment, the filter medium is pleatedor otherwise shaped or contoured to increase a surface area for passingthe intake airstream to be cleaned. In another exemplary embodiment, thefilter medium is configured to be treated with a filter oil compositionso as to enhance air cleaning properties of the filter medium.

In another exemplary embodiment, a wire support is incorporated into thefilter medium so as to provide additional strength and durability to thecone air filter. In another exemplary embodiment, the filter medium ispositioned between the wire support and one or more layers of areinforcing material. In another exemplary embodiment, the wire supportcomprises a wire screen positioned on an outer surface and a wire screenpositioned on an inner surface of the filter medium. In anotherexemplary embodiment, the wire screens are comprised of powder-coatedaluminum screen wire that is co-pleated along with the filter medium soas to reinforce the cone air filter.

In an exemplary embodiment, a method for a cone air filter for a closedintake system of an internal combustion engine comprises configuring abase that is comprised of a flange that couples with an air intake ductof the internal combustion engine; incorporating a shell receiver intothe base that receives a rigid exterior shell, such that the exteriorshell directs the intake airstream into the cone air filter; forming acap on an apex portion of the cone air filter to direct an intakeairstream into the cone air filter; fabricating a cone-shaped filtermedium to remove contaminants and particulate matter from the intakeairstream; and retaining the filter medium between the base and the cap.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an upper perspective view of an exemplary embodimentof a cone air filter comprising a cap that covers an apex portion of thecone air filter; and

FIG. 2 illustrates a lower perspective view of an exemplary embodimentof a cone air filter comprising a base configured to be coupled with anair intake of an internal combustion engine.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstflange,” may be made. However, the specific numeric reference should notbe interpreted as a literal sequential order but rather interpreted thatthe “first flange” is different than a “second flange.” Thus, thespecific details set forth are merely exemplary. The specific detailsmay be varied from and still be contemplated to be within the spirit andscope of the present disclosure. The term “coupled” is defined asmeaning connected either directly to the component or indirectly to thecomponent through another component. Further, as used herein, the terms“about,” “approximately,” or “substantially” for any numerical values orranges indicate a suitable dimensional tolerance that allows the part orcollection of components to function for its intended purpose asdescribed herein.

In general, the present disclosure describes an apparatus and a methodfor a cone air filter for a closed intake system of an internalcombustion engine. The cone air filter is configured to be retainedwithin a rigid exterior shell comprising the closed intake system, suchthat an intake airstream within an interior of the exterior shell isdrawn through a filter medium into an interior of the cone air filter.Contaminants and particulate matter are removed from the intakeairstream by the filter medium before the intake airstream is drawn intoan air intake duct to the internal combustion engine. The filter mediummay be comprised of paper, foam, cotton, spun fiberglass, or other knownfilter materials, woven or non-woven materials, synthetic or natural, orany combination thereof. A filter oil composition preferably is appliedto the filter medium so as to enhance air cleaning properties of thecone air filter. A base of the cone air filter includes a flange that isconfigured to couple with the air intake duct of the internal combustionengine. A cap comprising an apex portion of the cone air filter isconfigured to direct the intake airstream around the apex portion andinto the filter medium.

Although embodiments of the invention may be described and illustratedherein in terms of a cone air filter, it should be understood thatembodiments of this invention are not limited to the exact shapeillustrated, but rather may include a wide variety of generally enclosedshapes, such as cylindrical, circular, oval, round, curved, conical, orany other closed perimeter shape, that provide a relatively largesurface area in a given volume of the filter. Moreover, embodiments asdescribed herein are not limited to use as internal combustion enginefilters, but rather may have applicability in other filtration systemsin which a large volume of air needs to be treated.

FIG. 1 illustrates an upper perspective view of an exemplary embodimentof a cone air filter 100 configured for use within a closed intakesystem of an internal combustion engine. The cone air filter 100 iscomprised of a filter medium 104 disposed between a base 108 and a cap112. The cone air filter 100 is configured to be retained within a rigidexterior shell comprising the closed intake system, such that an intakeairstream is directed between the cap 112 and an interior of theexterior shell, drawn through the filter medium 104 into an interior ofthe cone air filter 100, and drawn into an air intake duct to theinternal combustion engine. The filter medium 104 is configured toremove contaminants and particulate matter from the intake airstreamthat is drawn into the air intake duct. The filter medium 104 is agenerally cone-shaped member comprised of an apex portion that isfixedly coupled with the cap 112, and a base portion that is affixed tothe base 108. The cap 112 serves to direct the intake airstream aroundthe apex portion of the cone air filter and into the filter medium 104.It is contemplated that the cap 112 is comprised of a rigid materialsuitable for withstanding the temperature and pressure within the closedintake system.

The base 108 includes a shell receiver 116 that is configured to receivean interior of the rigid exterior shell, such that the exterior shellsurrounds the cone air filter 100 and directs the intake airstream intothe filter medium 104, as described above. The shell receiver 116 iscomprised of a generally smooth circumferential surface disposed at anextreme diameter of the base 108. One or more holes 120 comprising theshell receiver 116 are configured to receive fasteners suitable forfixedly coupling the exterior shell with the smooth circumferentialsurface. In the embodiment illustrated in FIG. 1, the shell receiver 116is comprised of four holes 120 that are disposed uniformly along thesmooth circumferential surface around the perimeter of the base 108.

As best shown in FIG. 2, the base 108 is comprised of a flange 124 thatis configured to couple with an air intake duct of the internalcombustion engine. The flange 124 may be comprised of a pliable materialamendable to being stretched and compressed so as to be coupled withsizes of the air intake duct that are, respectively, slightly greaterthan or lessor than a relaxed interior diameter of an opening 128 of theflange 124. In some embodiments, the flange 124 may be configured toslide onto an exterior of the air intake duct and be retained thereon byway of a suitable clamp or any other similar fastener. In someembodiments, the flange 124 may be configured to receive an adaptor intothe opening 128 of the flange 124. It is contemplated that the adaptormay be configured to be coupled with the air intake duct so as tocommunicate the intake airstream from the interior of the cone airfilter 100 to the air intake duct.

Moreover, the base 108 includes a vent inlet receiver 132 that isconfigured to enable a practitioner of the cone air filter 100 toinstall a vent inlet, such that the vent inlet is placed into fluidcommunication with an interior of the cone air filter. For example, thevent inlet may be comprised of a flange adapter configured to couple theinterior of the cone air filter 100 with any of a PCV valve, a crankcasebreather, and various sensors that are electrically connected with theinternal combustion engine. In some embodiments, the vent inlet receiver132 may include a multiplicity of threads that are configured tothreadably engage with substantially similar threads disposed on anexterior of the vent inlet. In some embodiments, wherein the vent inletmay be omitted, a plug may be threadably installed into the vent inletreceiver 132 in lieu of the flange adapter.

As mentioned above, the filter medium 104 provides an area to pass theintake airstream and entrap particulates and other contaminates flowingwith the intake airstream. The filter medium 104 may be comprised ofpaper, foam, cotton, spun fiberglass, or other known filter materials,woven or non-woven materials, synthetic or natural, or any combinationthereof. The filter medium 104 may be pleated, or otherwise shaped, orcontoured so as to increase a surface area for passing the intakeairstream to be cleaned. The length of the filter medium 104 in thecircumferential direction may be longer than the circular circumferenceof the cone air filter 100 generally, such that the surface area of thefilter medium 104 is greater than the profile surface area of the coneair filter 100.

In some embodiments, a wire support may be incorporated into the filtermedium 104 so as to provide additional strength and durability to thecone air filter 100. For example, the filter medium 104 may bepositioned between the wire support and one or more layers of areinforcing material. The wire support may be comprised of wire screenspositioned on an outer surface and an inner surface of the filter medium104. In some embodiments, the filter medium 104 may be comprised of 4 to6 layers of cotton gauze that are sandwiched between two epoxy-coatedaluminum wire screens. It is contemplated that the wire screens may beco-pleated along with the filter medium 104 so as to reinforce the coneair filter 100. Further, the cotton gauze may be advantageously treatedwith a suitably formulated filter oil composition that causes tackinessthroughout microscopic strands comprising the filter medium 104. Thenature of the cotton allows high volumes of airflow, and when combinedwith the tackiness of the filter oil composition creates a powerfulfiltering medium which ensures a high degree of air filtration. Furtherdetails about components comprising the filter medium 104, as well asdetails about the filter oil composition, are disclosed in U.S. patentapplication Ser. No. 14/181,678, entitled “Air Box With IntegratedFilter Media,” filed on Feb. 16, 2014, and U.S. patent application Ser.No. 14/701,163, entitled “Filter Oil Formulation,” filed on Apr. 30,2015, the entirety of each of which is incorporated herein by reference.

It is contemplated that a practitioner of the cone air filter 100 mayperiodically clean the filter medium 104 rather than discarding theentire cone air filter, as is done with conventional air filters. In oneembodiment, a cleaning method may be comprised of removing the intakeair duct from the flange 124, and then removing any air ducting that iscoupled with the rigid exterior shell housing the cone air filter 100.Thus, the rigid exterior shell and cone air filter 100 may be removedtogether from the closed intake system. The practitioner may clean thecone air filter 100 while coupled with the rigid exterior shell, or thecone air filter may be first removed from the rigid exterior shellbefore being cleaned. In some embodiments, a method for cleaning thefilter medium 104 may be comprised of inserting a water hose through theopening 128 into the interior of the cone air filter 100 and thenspraying water so as to flush contaminants from the filter medium 104.In some embodiments, the method for cleaning the cone air filter 100 maybe comprised of utilizing a high pressure air hose in lieu of the waterhose. In some embodiments, the method for cleaning the cone air filter100 may be comprised of spraying water onto the exterior of the filtermedium 104, such that the water and contaminants are flushed directlyfrom the exterior of the filter medium 104, as well as exiting throughthe opening 128. Other cleaning methods will be apparent to thoseskilled in the art without deviating from the spirit and scope of thepresent disclosure.

While the invention has been described in tetras of particularvariations and illustrative figures, those of ordinary skill in the artwill recognize that the invention is not limited to the variations orfigures described. In addition, where methods and steps described aboveindicate certain events occurring in certain order, those of ordinaryskill in the art will recognize that the ordering of certain steps maybe modified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A cone air filter for a closed intake system ofan internal combustion engine, comprising: a base comprised of a flangethat is configured to couple with an air intake duct of the internalcombustion engine, wherein the base includes a vent inlet in fluidcommunication with an interior of the cone filter, wherein the flange iscomprised of a pliable material amendable to being stretched andcompressed so as to be coupled with sizes of the air intake duct thatare, respectively, greater than or lessor than a relaxed interiordiameter of the flange; the vent inlet is comprised of a flange adapterconfigured to couple the interior of the cone filter with any of a PCVvalve, a crankcase breather, and various sensors that are electricallyconnected with the internal combustion engine; a cap comprising an apexportion of the cone air filter and configured to direct an intakeairstream into the cone air filter; and a filter medium disposed betweenthe base and the cap, the filter medium being configured to removecontaminants and particulate matter from the intake airstream enteringthe air intake duct.
 2. The filter of claim 1, wherein the cone airfilter is configured to be retained within a rigid exterior shellcomprising the closed intake system, such that the intake airstream isdirected between the cap and an interior of the exterior shell, drawnthrough the filter medium into an interior of the cone air filter, thecontaminants and particulate matter being removed from the intakeairstream by the filter medium, and drawn into the air intake duct tothe internal combustion engine.
 3. The filter of claim 1, wherein thecap is comprised of a rounded, cone-shaped member fixedly coupled to anapex portion of the filter medium that is opposite of the base.
 4. Thefilter of claim 3, wherein the cap is comprised of a rigid materialsuitable for withstanding the temperature and pressure within the closedintake system, the cap being configured to direct the intake airstreamaround the apex portion and into the side of the filter medium.
 5. Thefilter of claim 1, wherein the base includes a shell receiver that isconfigured to receive a rigid exterior shell that directs the intakeairstream into the filter medium, the shell receiver being comprised ofa smooth circumferential surface disposed at an extreme diameter of thebase.
 6. The filter of claim 5, wherein the shell receiver is comprisedof one or more holes that are configured to receive fasteners suitablefor fixedly coupling the exterior shell with the smooth circumferentialsurface.
 7. The filter of claim 6, wherein the one or more holes arecomprised of four holes that are disposed uniformly around the perimeterof the smooth circumferential surface.
 8. The filter of claim 1, whereinthe flange is configured to slide onto an exterior of the air intakeduct and be retained thereon by way of a suitable clamp or any othersimilar fastener.
 9. The filter of claim 1, wherein the flange isconfigured to receive an adaptor into an interior of the flange, theadaptor being configured to be coupled with the air intake duct so as tocommunicate the intake airstream from the interior of the cone airfilter to the air intake duct.
 10. The filter of claim 1, wherein thefilter medium is comprised of paper, foam, cotton, spun fiberglass, orother known filter materials, woven or non-woven materials, synthetic ornatural, or any combination thereof.
 11. The filter of claim 1, whereinthe filter medium is pleated or otherwise shaped or contoured toincrease a surface area for passing the intake airstream to be cleaned.12. The filter of claim 1, wherein the filter medium is configured to betreated with a filter oil composition so as to enhance air cleaningproperties of the filter medium.
 13. The filter of claim 1, wherein awire support is incorporated into the filter medium so as to provideadditional strength and durability to the cone air filter.
 14. Thefilter of claim 13, wherein the filter medium is positioned between thewire support and one or more layers of a reinforcing material.
 15. Thefilter of claim 13, wherein the wire support comprises a wire screenpositioned on an outer surface and a wire screen positioned on an innersurface of the filter medium.
 16. The filter of claim 15, wherein thewire screens are comprised of powder-coated aluminum screen wire that isco-pleated along with the filter medium so as to reinforce the cone airfilter.
 17. A method for a cone air filter for a closed intake system ofan internal combustion engine, comprising: configuring a base that iscomprised of a flange that couples with an air intake duct of theinternal combustion engine, wherein the base includes a vent inletreceiver configured to receive a vent inlet, such that the vent inlet isplaced into fluid communication with an interior of the cone filter,wherein the flange is comprised of a pliable material amendable to beingstretched and compressed so as to be coupled with sizes of the airintake duct that are, respectively, greater than or lessor than arelaxed interior diameter of the flange; incorporating a shell receiverinto the base that receives a rigid exterior shell, such that theexterior shell directs the intake airstream into the cone air filter;forming a cap on an apex portion of the cone air filter to direct anintake airstream into the cone air filter; fabricating a cone-shapedfilter medium to remove contaminants and particulate matter from theintake airstream; and retaining the filter medium between the base andthe cap.
 18. The method of claim 17, wherein the cone air filter isconfigured to be retained within a rigid exterior shell comprising theclosed intake system, such that the intake airstream is directed betweenthe cap and an interior of the exterior shell, drawn through the filtermedium into an interior of the cone air filter, the contaminants andparticulate matter being removed from the intake airstream by the filtermedium, and drawn into the air intake duct to the internal combustionengine.
 19. The method of claim 17, wherein the cap is comprised of arounded, cone-shaped member fixedly coupled to an apex portion of thefilter medium that is opposite of the base.
 20. The method of claim 19,wherein the cap is comprised of a rigid material suitable forwithstanding the temperature and pressure within the closed intakesystem, the cap being configured to direct the intake airstream aroundthe apex portion and into the side of the filter medium.